AutoZone 2008 GMC Truck Envoy 4WD 4.2L SFI DOHC 6cyl | Repair Guides | Brakes | Rear Disc Brakes | Brake Caliper | AutoZone.com

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    2008 GMC Truck Envoy 4WD 4.2L SFI DOHC 6cyl

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    Ford Windstar 1999-2003

    Brake Caliper

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    Removal & Installation



    1. Remove the brake master cylinder reservoir cap. Siphon and recycle approximately half the fluid from the reservoir.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the wheels.
    6.  
    7. Matchmark the brake caliper to ensure that it will be installed on the proper side of the vehicle.
    8.  
    9. Place a drain pan under the caliper to catch dripping brake fluid.
    10.  
    11. Remove the hollow retaining bolt that connects the hose to the caliper. Discard the copper washers.
    12.  
    13. Remove the brake hose and cap to prevent the entry of moisture or dirt.
      NOTE
      Do not press against the brake pad spring clip.

    14.  
    15. Position the C-clamp frame on the inboard side of the rear disc brake caliper housing. Position the clamp screw on the outboard brake pad backing plate.
    16.  
    17. Tighten the C-clamp sufficiently to press the rear disc brake caliper piston to the bottom of the caliper bore.
    18.  
    19. Remove the caliper bolts.
      NOTE
      Do not allow the caliper to hang by the rear brake hose.

    20.  
    21. Work the caliper off the rear disc brake rotor and brake adapter.

      Click image to see an enlarged view

      Fig. Exploded view of a rear disc brake assembly

    22.  

    To install:


    NOTE
    To prevent interference with rear disc brake caliper operation, verify correct caliper bolt length. The shank portion including the threads of the caliper bolt should not be more than 2.613-2.661 in. (66.4-67.6mm).

    1. Install the rear disc brake caliper on the rotor. Make sure the notches on the upper ends of the brake pad are seated over the upper ledge of the adapter and the brake pad lower tabs are positioned on the lower ledge of the adapter.
    2.  
    3. Lubricate the caliper bolts with Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent. Install and tighten to 11-14 ft. lbs. (15-20 Nm).
      NOTE
      Failure to tighten the lug nuts to the proper torque in a star pattern may result in damage to the brake rotor.

    4.  
    5. Connect the brake hose, using two new copper washers and tighten the hollow bolt to 35-46 ft. lbs. (47-63 Nm).
    6.  
    7. Fill the master cylinder fluid reservoir with clean, fresh brake fluid meeting or exceeding DOT 3 specifications.
    8.  
    9. Bleed the brake system.
    10.  
    11. Install the wheel and tighten lug nuts to 83-112 ft. lbs. (113-153 Nm).
    12.  
    13. Lower the vehicle.
    14.  

    1. Remove and discard 1 / 2 of the brake fluid from the brake master cylinder reservoir.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the wheel and tire assembly.
    6.  
    7. Disconnect the brake hose from the disc brake caliper by loosening and removing the hollow retaining bolt. Discard 2 copper sealing washers and plug the brake hose.
    8.  
    9. Using a C-clamp or equivalent, position the clamp frame on the inboard side of the disc brake caliper housing. Place the clamp screw on the outboard disc brake pad and tighten the clamp enough to press the caliper piston into the caliper housing releasing pressure on the disc brake pads.
    10.  
    11. Remove 2 disc brake caliper retaining bolts.
    12.  
    13. Remove the caliper by swinging out the bottom of the caliper first.
    14.  
    15. Remove the disc brake pads, if necessary.
    16.  

    To install:

    1. Retract the disc brake caliper piston fully into the caliper bore using a C-clamp and block of wood or equivalent.
    2.  
    3. Ensure that the disc brake pads are properly positioned and that the lining material is facing the rotor.
    4.  
    5. Install the caliper over the disc brake rotor and position on the brake adapter. Install 2 disc brake caliper retaining bolts and tighten to 11-14 ft. lbs. (15-20 Nm).

      Click image to see an enlarged view

      Fig. Rear disc brake caliper mounting-Windstar

    6.  
    7. Unplug and install the brake hose and hollow retaining bolt to the disc brake caliper using a new copper sealing washer on each side of the hose fitting. Tighten the retaining bolt to 35-46 ft. lbs. (47-63 Nm).
    8.  
    9. Bleed the brake system and install the rubber bleeder screw caps when complete.
    10.  
    11. Install the wheel and tire assembly. Torque the lug nuts to 85-105 ft. lbs. (115-142 Nm).
    12.  
    13. Lower the vehicle.
    14.  
    15. Pump the brake pedal several times to position the brake pads before attempting to move the vehicle.
    16.  
    17. Check and fill the brake master cylinder as required.
    18.  
    19. Road-test the vehicle and check for proper brake operation.
    20.  

     
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